| Troubleshooting − Excessive Spatter | |
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| Excessive Spatter − scattering of molten metal particles that |
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| cool to solid form near weld bead. |
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| Possible Causes | Corrective Actions |
Wire feed speed too high. | Select lower wire feed speed. | |
Voltage too high. | Select lower voltage range. | |
Electrode extension (stickout) too long. | Use shorter electrode extension (stickout). | |
Workpiece dirty. | Remove all grease, oil, moisture, rust, paint, undercoating, and dirt from work surface before welding. | |
Insufficient shielding gas at welding arc. | Increase flow of shielding gas at regulator/flowmeter and/or prevent drafts near welding arc. | |
Dirty welding wire. | Use clean, dry welding wire. | |
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| Eliminate pickup of oil or lubricant on welding wire from feeder or liner. |
| Troubleshooting − Porosity | |
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| Porosity − small cavities or holes resulting from gas pockets |
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| in weld metal. |
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| Possible Causes | Corrective Actions |
Insufficient shielding gas at welding arc. | Increase flow of shielding gas at regulator/flowmeter and/or prevent drafts near welding arc. | |
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| Remove spatter from gun nozzle. |
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| Check gas hoses for leaks. |
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| Place nozzle 1/4 to 1/2 in |
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| Hold gun near bead at end of weld until molten metal solidifies. |
Wrong gas. | Use welding grade shielding gas; change to different gas. | |
Dirty welding wire. | Use clean, dry welding wire. | |
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| Eliminate pick up of oil or lubricant on welding wire from feeder or liner. |
Workpiece dirty. | Remove all grease, oil, moisture, rust, paint, coatings, and dirt from work surface before welding. | |
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| Use a more highly deoxidizing welding wire (contact supplier). |
Welding wire extends too far out of nozzle. | Be sure welding wire extends not more than 1/2 in (13 mm) beyond nozzle. | |
| Troubleshooting − Excessive Penetration | |
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| Excessive Penetration − weld metal melting through base metal |
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| and hanging underneath weld. |
| Excessive Penetration Good Penetration | |
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| Possible Causes | Corrective Actions |
Excessive heat input. | Select lower voltage range and reduce wire feed speed. | |
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| Increase travel speed. |
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